imately at the upper COLD hole of the dipstick at
70É F fluid temperature.
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
(1) Start engine and apply parking brake.
(2) Shift the transmission into DRIVE for approxi-
mately 2 seconds.
(3) Shift the transmission into REVERSE for
approximately 2 seconds.
(4) Shift the transmission into PARK.
(5) Hook up DRBtscan tool and select transmis-
sion.
(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the
chart. (Fig. 66)
(9) Adjust transmission fluid level shown on the
dipstick according to the chart.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmission for leaks.STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper service intervals (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION).
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Place a large diameter shallow drain pan
beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to
transmission.
(4) Loosen bolts holding rear of pan to transmis-
sion.
(5) Slowly separate front of pan away from trans-
mission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolts hold-
ing pan to transmission.
(7) While holding pan level, lower pan away from
transmission.
(8) Pour remaining fluid in pan into drain pan.
(9) Remove screw holding filter to valve body (Fig.
67).
(10) Separate filter from valve body and oil pump
and pour fluid in filter into drain pan.
Fig. 66 Transmission Fluid Temperature Chart
DRAUTOMATIC TRANSMISSION - 45RFE/545RFE 21 - 367
FLUID AND FILTER (Continued)
Adhesion Promoter/Surface Modifier:
Adhesion Promoters/Surface Modifiers are required
for certain plastics. All three categories may have
plastics that require the use of adhesion promoter/
surface modifiers. Always follow repair material man-
ufacturer's plastic identification and repair
procedures.
SAFETY PRECAUTION AND WARNINGS
WARNING:
²EYE PROTECTION SHOULD BE USED WHEN
SERVICING COMPONENTS. PERSONAL INJURY
CAN RESULT.
²USE AN OSHA APPROVED BREATHING MASK
WHEN MIXING EPOXY, GRINDING, AND SPRAYING
PAINT OR SOLVENTS IN A CONFINED AREA. PER-
SONAL INJURY CAN RESULT.²AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
²DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
SAFETY STANDS. PERSONAL INJURY CAN
RESULT.
NOTE:
²When holes must be drilled or cut in body pan-
els, verify locations of internal body components
and electrical wiring. Damage to vehicle can result.
²Do not use abrasive chemicals or compounds
on undamaged painted surfaces around repair
areas. Damage to finish can result.
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION
ASA ACRYLONITRILE STYRENE
ACRYLITELURAN S CONSOLES, GRILLES
ABS ACRYLONITRILE
BUTADIENE STYRENETERLURAN9A9PILLARS, CONSOLES,
GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN,
CYCLOVINDOOR PANELS, GRILLES,
TRIM
BMC BULK MOLDING
COMPOUNDBMC FENDER EXTENSIONS
EMA EHTYLENE METHYL
ACRYLATE/IONOMERSURLYN, EMA, IONOMER BUMPER GUARDS, PADS
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED
POLYPHENYLENE OXIDEMPPO SPOILER ASSEMBLY
PA POLYAMID ZYTEL, VYDYNE, PA,
MINLONFENDERS, QUARTER
PANELS
PET THERMOPLASTIC
POLYESTERRYNITE TRIM
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE
THEREPTHALATEPBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
GRILLES
PBTP/EEBC POLYBUTYLENE
THEREPTHALATE/EEBC
ALLOYBEXLOY,9M9, PBTP/EEBC FASCIAS, ROCKER PANEL,
MOLDINGS
PC POLYCARBONATE LEXAN, MERLON, CALIBRE,
MAKROLON PCTAIL LIGHT LENSES, IP TRIM,
VALANCE PANELS
23 - 4 BODYDR
BODY (Continued)
(2) Disconnect the refrigerant lines from the A/C
compressor. Cap open lines to prevent moisture from
entering the system.
(3) Remove the A/C compressor from the vehicle.
(4) From the suction and discharge ports on the
A/C compressor, drain the lubricant from the old A/C
compressor into a clean container.
(5) From the suction and discharge ports on the
A/C compressor, drain the lubricant from the new
A/C compressor into a clean container.
(6) Install new lubricant back into the new A/C
compressor in the amount measured from the used
compressor, plus adding any amount of lubricant lost
when the refrigerant system was reclaimed.
(7) Install the A/C compressor and connect the
refrigerant lines. Then evacuate and charge refriger-
ant system.
SERVICE PORT VALVE CORE
DESCRIPTION
A/C SERVICE PORT VALVE CORES
The A/C service port valve cores are serviceable
items. The A/C pressure transducer is mounted on
the high side service port which is located on the dis-
charge line near the A/C compressor. The low side
service port is located on the suction line near the
accumulator outlet tube.
REMOVAL - SERVICE PORT VALVE CORES
WARNING: REFER TO THE APPLICABLE WARN-
INGS AND CAUTIONS FOR THIS SYSTEM BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
(1) Remove the protective cap from the low side
service port as necessary.
(2) Remove the A/C pressure transducer from the
high side service port as necessary (Refer to 24 -
HEATING & AIR CONDITIONING/CONTROLS/A/C
PRESSURE TRANSDUCER - REMOVAL).
(3) Recover the refrigerant from the refrigerant
system (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING/REFRIGERANT - STANDARD
PROCEDURE).
(4) Using a standard Schrader-type valve core tool,
remove the valve core from the service ports as
required.
(5) Install a plug in or tape over the opened ser-
vice port(s).
INSTALLATION
(1) Lubricate the A/C service port valve core with
clean refrigerant oil prior to installation. Use only
refrigerant oil of the type recommended for the A/C
compressor in the vehicle.
(2) Remove the tape or plug from the A/C service
port.
CAUTION: A valve core that is not fully seated in
the A/C service port can result in damage to the
valve during refrigerant system evacuation and
charge. Such damage may result in a loss of sys-
tem refrigerant while uncoupling the charge adapt-
ers.
(3) Using a standard Schrader-type valve core tool,
install and tighten the replacement valve core into
the A/C service ports as required.
(4) Evacuate the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM EVACUATE).
(5) Charge the refrigerant system (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
FRONT/REFRIGERANT - STANDARD PROCE-
DURE - REFRIGERANT SYSTEM CHARGE).
(6) Install the A/C pressure transducer to the high
side service port as necessary (Refer to 24 - HEAT-
ING & AIR CONDITIONING/CONTROLS/A/C
PRESSURE TRANSDUCER - INSTALLATION).
(7) Install the protective cap onto the A/C service
ports as required.
SUCTION LINE
DESCRIPTION
The suction line is the refrigerant line that goes
from the evaporator outlet tube to the compressor
inlet port. The suction line for the 5.9L Diesel engine
is only serviced as an assembly with the discharge
line. The suction line has no serviceable parts except
the rubber O-rings. If the suction line is found to be
leaking or is damaged, it must be replaced.
REMOVAL
REMOVAL - 5.9L DIESEL ENGINE
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMBING -
WARNING) and (Refer to 24 - HEATING & AIR CON-
DITIONING/PLUMBING - CAUTION).
24 - 70 PLUMBINGDR
REFRIGERANT OIL (Continued)
CONTROL MODULE - DESCRIPTION,
AIRBAG............................8O-11
CONTROL MODULE - DESCRIPTION,
FRONT...........................8W-97-5
CONTROL MODULE - DESCRIPTION,
FRONT..............................8E-5
CONTROL MODULE - DESCRIPTION,
TRANSFER CASE.....................8E-16
CONTROL MODULE - DESCRIPTION,
TRANSMISSION......................8E-20
CONTROL MODULE - DIAGNOSIS AND
TESTING, FRONT...................8W-97-5
CONTROL MODULE - DIAGNOSIS AND
TESTING, FRONT......................8E-5
CONTROL MODULE - INSTALLATION,
AIRBAG............................8O-13
CONTROL MODULE - INSTALLATION,
ENGINE.............................8E-4
CONTROL MODULE - INSTALLATION,
FRONT...........................8W-97-6
CONTROL MODULE - INSTALLATION,
FRONT..............................8E-5
CONTROL MODULE - OPERATION,
AIRBAG............................8O-11
CONTROL MODULE - OPERATION,
FRONT...........................8W-97-5
CONTROL MODULE - OPERATION,
FRONT..............................8E-5
CONTROL MODULE - OPERATION,
TRANSFER CASE.....................8E-16
CONTROL MODULE - OPERATION,
TRANSMISSION......................8E-20
CONTROL MODULE - REMOVAL, AIRBAG . 8O-12
CONTROL MODULE - REMOVAL, ENGINE . . . 8E-4
CONTROL MODULE - REMOVAL, FRONT . 8W-97-6
CONTROL MODULE - REMOVAL, FRONT . . . 8E-5
CONTROL MOTOR - DESCRIPTION, IDLE
AIR ...............................14-28
CONTROL MOTOR - INSTALLATION, IDLE
AIR ...............................14-29
CONTROL MOTOR - OPERATION, IDLE
AIR ...............................14-28
CONTROL MOTOR - REMOVAL, IDLE AIR . . 14-29
CONTROL RELAY - DESCRIPTION,
TRANSMISSION.....................21-405
CONTROL RELAY - OPERATION,
TRANSMISSION.....................21-405
CONTROL SWITCH - DESCRIPTION,
LUMBAR...........................8N-17
CONTROL SWITCH - OPERATION,
LUMBAR...........................8N-18
CONTROL SWITCH - REMOVAL,
LUMBAR...........................8N-18
CONTROLLED VISCOUS FAN DRIVE -
DIAGNOSIS AND TESTING,
ELECTRONICALLY.....................7-52
CONTROLLER ANTILOCK BRAKE -
DESCRIPTION........................8E-3
CONTROLLER ANTILOCK BRAKE -
INSTALLATION........................8E-3
CONTROLLER ANTILOCK BRAKE -
OPERATION..........................8E-3
CONTROLLER ANTILOCK BRAKE -
REMOVAL...........................8E-3
CONTROLS - DIAGNOSIS AND TESTING,
OVERDRIVE ELECTRICAL.............21-262
CONVERTER - DESCRIPTION, CATALYTIC
. . . 11-6
CONVERTER - DESCRIPTION, TORQUE
. . 21-255,
21-399
CONVERTER - INSTALLATION, TORQUE
. . 21-260,
21-404
CONVERTER - OPERATION, CATALYTIC
....11-6
CONVERTER - OPERATION, TORQUE
....21-259,
21-403
CONVERTER - REMOVAL, TORQUE
.....21-260,
21-404
CONVERTER DRAINBACK VALVE -
DESCRIPTION, TORQUE
..............21-261
CONVERTER DRAINBACK VALVE -
OPERATION, TORQUE
................21-261
CONVERTER DRAINBACK VALVE -
STANDARD PROCEDURE, TORQUE
......21-261
CONVERTER HOUSING FLUID LEAK -
DIAGNOSIS AND TESTING
......21-144,21-318
COOLANT - DESCRIPTION, ENGINE
.......7-31
COOLANT - DESCRIPTION, ENGINE
........0-3
COOLANT - DESCRIPTION, HOAT
.........7-32COOLANT - STANDARD PROCEDURE,
ADDING ADDITIONAL..................7-19
COOLANT FLOW - DIAGNOSIS AND
TESTING, RADIATOR...............7-54,7-56
COOLANT LEVEL CHECK - STANDARD
PROCEDURE.........................7-17
COOLANT RECOVERY CONTAINER- GAS
ENGINES - DESCRIPTION...............7-33
COOLANT RECOVERY CONTAINER- GAS
ENGINES - INSTALLATION...............7-33
COOLANT RECOVERY CONTAINER- GAS
ENGINES - OPERATION.................7-33
COOLANT RECOVERY CONTAINER- GAS
ENGINES - REMOVAL..................7-33
COOLANT TEMPERATURE SENSOR -
DESCRIPTION, ENGINE.................7-38
COOLANT TEMPERATURE SENSOR -
INSTALLATION, ENGINE................7-41
COOLANT TEMPERATURE SENSOR -
OPERATION, ENGINE...................7-38
COOLANT TEMPERATURE SENSOR -
REMOVAL, ENGINE....................7-39
COOLANT THERMOSTAT - 3.7L/4.7L -
DESCRIPTION, ENGINE.................7-44
COOLANT THERMOSTAT - 3.7L/4.7L -
INSTALLATION, ENGINE................7-45
COOLANT THERMOSTAT - 3.7L/4.7L -
OPERATION, ENGINE...................7-44
COOLANT THERMOSTAT - 3.7L/4.7L -
REMOVAL, ENGINE....................7-45
COOLANT THERMOSTAT - 5.9L DIESEL -
DESCRIPTION, ENGINE.................7-46
COOLANT THERMOSTAT - 5.9L DIESEL -
INSTALLATION, ENGINE..................7-47
COOLANT THERMOSTAT - 5.9L DIESEL -
OPERATION, ENGINE...................7-46
COOLANT THERMOSTAT - 5.9L DIESEL -
REMOVAL, ENGINE....................7-47
COOLANT THERMOSTAT - 8.0L -
DESCRIPTION, ENGINE.................7-48
COOLANT THERMOSTAT - 8.0L -
INSTALLATION, ENGINE................7-49
COOLANT THERMOSTAT - 8.0L -
OPERATION, ENGINE...................7-48
COOLANT THERMOSTAT - 8.0L -
REMOVAL, ENGINE....................7-49
COOLANT THERMOSTAT-5.7L -
DESCRIPTION, ENGINE.................7-41
COOLANT THERMOSTAT-5.7L -
INSTALLATION, ENGINE................7-43
COOLANT THERMOSTAT-5.7L -
OPERATION, ENGINE...................7-41
COOLANT THERMOSTAT-5.7L -
REMOVAL, ENGINE....................7-42
COOLER - 5.9L DIESEL - DESCRIPTION,
TRANS..............................7-68
COOLER - 5.9L DIESEL - OPERATION,
TRANS..............................7-69
COOLER - DESCRIPTION, TRANS.........7-67
COOLER - INSTALLATION, AIR TO OIL.....7-70
COOLER - INSTALLATION, FLUID........19-43
COOLER - INSTALLATION, RETURN
HOSE - GEAR TO................19-44,19-45
COOLER - INSTALLATION, RETURN
HOSE - RESERVOIR TO...........19-44,19-45
COOLER - INSTALLATION, TRANS........7-68
COOLER - INSTALLATION, WATER-TO-
AIR
................................7-70
COOLER - OPERATION, TRANS
...........7-67
COOLER - REMOVAL, AIR TO OIL
.........7-69
COOLER - REMOVAL, FLUID
............19-43
COOLER - REMOVAL, RETURN HOSE -
GEAR TO
......................19-44,19-45
COOLER - REMOVAL, RETURN HOSE -
RESERVOIR TO
.................19-44,19-45
COOLER - REMOVAL, TRANS
............7-68
COOLER - REMOVAL, WATER TO OIL
......7-69
COOLER AND PLUMBING - CLEANING,
CHARGE AIR
........................11-17
COOLER AND PLUMBING -
DESCRIPTION, CHARGE AIR
............11-16
COOLER AND PLUMBING - INSPECTION,
CHARGE AIR
........................11-17
COOLER AND PLUMBING -
INSTALLATION, CHARGE AIR
...........11-17
COOLER AND PLUMBING - OPERATION,
CHARGE AIR
........................11-16COOLER AND PLUMBING - REMOVAL,
CHARGE AIR........................11-17
COOLER SYSTEM - LEAKS - DIAGNOSIS
AND TESTING, CHARGE AIR............11-16
COOLING, SPECIAL TOOLS..............7-20
COOLING SYSTEM - ALL GAS ENGINES -
STANDARD PROCEDURE, DRAINING......7-17
COOLING SYSTEM - ALL GAS ENGINES -
STANDARD PROCEDURE, REFILLING......7-18
COOLING SYSTEM - OPERATION..........7-5
COOLING SYSTEM - TESTING FOR
LEAKS - DIAGNOSIS AND TESTING........7-5
COOLING SYSTEM 5.9L DIESEL ENGINE
- STANDARD PROCEDURE, DRAINING.....7-18
COOLING SYSTEM 5.9L DIESEL ENGINE
- STANDARD PROCEDURE, REFILLING.....7-19
COOLING SYSTEM CLEANING/REVERSE
FLUSHING - STANDARD PROCEDURE.....7-17
COOLING SYSTEM DIESEL ENGINE -
DIAGNOSIS AND TESTING...............7-7
COOLING SYSTEM FLOW - 5.9L DIESEL
- DESCRIPTION........................7-3
COOLING SYSTEM FLOW 3.7L/4.7L/5.7L
ENGINE - DESCRIPTION.................7-1
COOLING SYSTEM REQUIREMENTS -
DESCRIPTION, ENGINE.................24-1
COOLING SYSTEM, WARNING - ENGINE . . 24-42
CORE - DESCRIPTION, HEATER.........24-63
CORE - DESCRIPTION, SERVICE PORT
VALVE .............................24-70
CORE - INSTALLATION, HEATER.........24-63
CORE - INSTALLATION, SERVICE PORT
VALVE .............................24-70
CORE - OPERATION, HEATER...........24-63
CORE - REMOVAL, HEATER............24-63
CORE HOLE PLUG - INSTALLATION,
CAMSHAFT.........................9-206
CORE HOLE PLUG - REMOVAL,
CAMSHAFT.........................9-205
CORE PLUGS - INSTALLATION..........9-131
CORE PLUGS - REMOVAL..............9-131
CORES - REMOVAL, SERVICE PORT
VALVE .............................24-70
COUPLER - DESCRIPTION,
REFRIGERANT LINE...................24-67
COUPLER - INSTALLATION,
REFRIGERANT LINE...................24-68
COUPLER - OPERATION, REFRIGERANT
LINE...............................24-67
COUPLER - REMOVAL, REFRIGERANT
LINE...............................24-68
COUPLING - INSTALLATION, UPPER
STEERING..........................19-13
COUPLING - REMOVAL, UPPER
STEERING..........................19-13
COVER - DESCRIPTION, STRUCTURAL . . . 9-145,
9-216,9-57
COVER - FRONT - INSTALLATION, SEAT
BACK CUSHION......................23-82
COVER - FRONT - INSTALLATION, SEAT
CUSHION...........................23-83
COVER - FRONT - REMOVAL, SEAT BACK
CUSHION...........................23-82
COVER - FRONT - REMOVAL, SEAT
CUSHION...........................23-83
COVER - INSTALLATION...............23-16
COVER - INSTALLATION, ACM
..........8O-10
COVER - INSTALLATION, CENTER SEAT
BACK INERTIA HINGE
.................23-77
COVER - INSTALLATION, CENTER SEAT
CUSHION
...........................23-79
COVER - INSTALLATION, CYLINDER
HEAD
..............................9-255
COVER - INSTALLATION, DIFFERENTIAL
....3-97
COVER - INSTALLATION, GEAR HOUSING
. 9-301
COVER - INSTALLATION, INSTRUMENT
PANEL TOP
.........................23-59
COVER - INSTALLATION, REAR DOOR
SILL TRIM
..........................23-71
COVER - INSTALLATION, SHIFT
. . . 21-129,21-87
COVER - INSTALLATION, STEERING
COLUMN OPENING
...................23-60
COVER - INSTALLATION, STRUCTURAL
. . . 9-145,
9-216,9-57
COVER - INSTALLATION, TIMING/CHAIN
. . 9-227
COVER - OPERATION, STRUCTURAL
.....9-145,
9-216,9-57
8 INDEXDR
Description Group-Page Description Group-Page Description Group-Page